U.S. patent application number 15/817727 was filed with the patent office on 2018-03-15 for assembling and handling edge interconnect packaging system.
The applicant listed for this patent is Indiana Integrated Circuits, LLC. Invention is credited to Jason M. Kulick, Tian Lu.
Application Number | 20180077801 15/817727 |
Document ID | / |
Family ID | 51526174 |
Filed Date | 2018-03-15 |
United States Patent
Application |
20180077801 |
Kind Code |
A1 |
Kulick; Jason M. ; et
al. |
March 15, 2018 |
Assembling and Handling Edge Interconnect Packaging System
Abstract
Apparatuses and methods related to the field of microchip
assembly and handling, in particular to devices and methods for
assembling and handling microchips manufactured with solid
edge-to-edge interconnects, such as Quilt Packaging.RTM.
interconnect technology. Specialized assembly tools are configured
to pick up one or more microchips, place the microchips in a
specified location aligned to a substrate, package, or another
microchip, and facilitate electrical contact through one of a
variety of approaches, including solder reflow. This specialized
assembly tooling performs heating functions to reflow solder to
establish electrical and mechanical interconnections between
multiple microchips. Additionally, the interconnected microchips
may be arranged in an arbitrarily large array.
Inventors: |
Kulick; Jason M.; (South
Bend, IN) ; Lu; Tian; (Osceola, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Indiana Integrated Circuits, LLC |
South Bend |
IN |
US |
|
|
Family ID: |
51526174 |
Appl. No.: |
15/817727 |
Filed: |
November 20, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14211127 |
Mar 14, 2014 |
9844139 |
|
|
15817727 |
|
|
|
|
61802504 |
Mar 16, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H05K 1/181 20130101;
Y10T 29/49128 20150115; H05K 3/34 20130101; Y02P 70/50 20151101;
Y02P 70/611 20151101; H05K 1/18 20130101; H05K 2201/1053
20130101 |
International
Class: |
H05K 1/18 20060101
H05K001/18 |
Claims
1. A microchip unit comprising: a first microchip having a set of
first nodules located along and projecting substantially from an
edge of the first microchip, wherein the edge of the first
microchip is defined at an intersection of a top surface and
another surface of the first microchip; a second microchip having a
set of second nodules located along and projecting substantially
from an edge of the second microchip, wherein the edge of the
second microchip is defined at an intersection of a top surface and
another surface of the second microchip; and a substrate having a
conductive segment or contact, wherein: the first and second
microchips are positioned top-face down on the substrate with the
first and second sets of nodules joined with each other with the
first and second microchips in spaced relation and with the
conductive segment or contact joined to one nodule of the set of
first nodules and one nodule of the set of second nodules.
2. The microchip unit of claim 1, wherein a surface of at least one
nodule of the first set of nodules is generally coplanar with the
top surface of the first microchip.
3. The microchip unit of claim 2, wherein a surface of at least one
nodule of the second set of nodules is generally coplanar with the
top surface of the second microchip.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S. patent
application Ser. No. 14/211,127, filed Mar. 14, 2014, which claims
priority from U.S. Provisional Application No. 61/802,504, filed
Mar. 16, 2013, both of which are incorporated herein in their
entireties by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The described apparatuses and methods relate to the field of
microchip handling and assembly. More particularly, the described
apparatus and methods relate to the handling and assembly of
microchips configured with solid edge-to-edge interconnects.
Description of Related Art
[0003] Generally, electronic systems are comprised of multiple
discrete microchips. These microchips work together, along with
other peripheral devices, to accomplish particular tasks. For the
system to function, the discrete microchips must be electrically
connected, both to each other and to any other components contained
within the system. A wide variety of methods presently exists to
accomplish this connectivity, including wire-bonding, bump-bonding,
flip-chip, through-silicon-via (TSV), and chip-on-board. Each of
these methods is specialized to function with an associated
interconnect technology. Specialized assembly and packaging tools
are used to handle, align, interconnect, and package microchips.
These tools must be designed to accommodate the particular
packaging and interconnection approach selected. As new
interconnect technologies are created, it becomes necessary to
develop new specialized methods and tools to effectively connect
microchips using the new technology. Accordingly, there exists a
need for new assembly methods and apparatuses that are capable of
functioning with cutting-edge interconnect technologies.
SUMMARY OF THE INVENTION
[0004] The following presents a simplified summary in order to
provide a basic understanding of some aspects of the claimed
subject matter. This summary is not an extensive overview. It is
not intended either to identify key or critical elements or to
delineate the scope of the claimed subject matter. Its sole purpose
is to present some concepts in a simplified form as a prelude to
the more detailed description that is presented later.
[0005] With the creation of microchips configured with solid
edge-to-edge interconnects, a need has arisen for new, specialized
tools and methods to effectively connect discrete microchips
together. For example, existing methods are incapable of the
precision alignment required to connect multiple edge-based contact
points. Further, existing methods are inadequate at reliably
forming functional mechanical and electrical connections directly
between adjacent microchips.
[0006] Accordingly, the described apparatuses and methods relate to
the field of microchip assembly and handling, in particular to
devices and methods for assembling and handling microchips
manufactured with solid edge-to-edge interconnects, such as Quilt
Packaging.RTM. interconnect technology. Specialized assembly tools
are described that are configured to pick up one or more
microchips, place the microchips in a specified location aligned to
a substrate, package, or another microchip, and facilitate
electrical contact through one of a variety of approaches,
including solder reflow. This specialized assembly tooling performs
heating functions to reflow solder to establish electrical and
mechanical interconnections between multiple microchips.
[0007] In an embodiment, after two or more microchips have been
positioned and interconnected on a package, the assembly tooling
can finish either by sealing the package with a cover or sealant or
by moving the assembled unit along for further processing.
[0008] In an embodiment, a device is capable of performing the
precision alignment needed to join solid edge-to-edge interconnect
structures and prevent lateral movement and pressure during solder
reflow. In another embodiment, vacuum is used to hold multiple
microchips in place while additional microchips of the same or
varying geometries, sizes, and thicknesses are aligned into an
interconnected array or quilt. In an embodiment, microchips can be
assembled into such an array either on a stage and then reflowed or
alternatively assembled directly on a package or substrate and
reflowed. In an embodiment, microchips can be assembled either
orthogonally or at other angles to one another. After assembly, the
array of interconnected microchips can be moved into a package,
onto a substrate or board, encapsulated, or otherwise protected by
the application of a protective material, such as an epoxy or
polymer.
[0009] To the accomplishment of the foregoing and related ends,
certain illustrative aspects of the claimed subject matter are
described herein in connection with the following description and
the annexed drawings. These aspects are indicative of various ways
in which the subject matter may be practiced, all of which are
intended to be within the scope of the claimed subject matter.
Other advantages and novel features may become apparent from the
following detailed description when considered in conjunction with
the drawings.
[0010] More specifically, disclosed herein is a method for
interconnecting microchips comprising: (a) positioning a first
microchip using a first manipulator, wherein the first microchip
has a set of first nodules located on an edge of the first
microchip; (b) securing the first microchip in place; (c)
positioning a second microchip using a second manipulator, wherein
the second microchip has a set of second nodules located on an edge
of the second microchip; (d) moving the second microchip so that
the set of second nodules is positioned proximate to the set of
first nodules; (e) securing the second microchip in place; and (f)
joining the set of first nodules to the set of second nodules to
interconnect the first and second microchips.
[0011] The set of first nodules can be located closest to a top
face of the first microchip. The set of second nodules can be
located closest to a top face of the second microchip.
[0012] The first microchip and the second microchip can be
positioned top-face down on a substrate. The substrate can include
a conductive segment or contact that is joined to one nodule of the
set of first nodules and one nodule of the set of second nodules
when the first second microchips are positioned top-face down on
the substrate.
[0013] The sets of first and second nodules can maintain the first
and second microchips in spaced relation when the first and second
sets of nodules and the conductive segment or contact are
joined.
[0014] The edge of the first microchip can be defined by the
intersection of a top face of the first microchip and a side of the
first microchip. The edge of the second microchip can be defined by
the intersection of a top face of the second microchip and a side
of the second microchip.
[0015] The first microchip and the second microchip can be
positioned top-face down on a substrate. The substrate can include
a conductive segment or contact. The method can include joining the
conductive segment or contact to one nodule of the set of first
nodules and one nodule of the set of second nodules.
[0016] Each set of nodules can include at least one nodule.
[0017] Also disclosed herein is a microchip unit comprising: a
first microchip having a set of first nodules located along and
projecting from an edge of the first microchip, wherein the edge of
the first microchip is defined at an intersection of a top surface
and another surface of the first microchip; a second microchip
having a set of second nodules located along and projecting from an
edge of the second microchip, wherein the edge of the second
microchip is defined at an intersection of a top surface and
another surface of the second microchip; and a substrate having a
conductive segment or contact. The first and second microchips are
positioned top-face down on the substrate with the first and second
sets of nodules joined with each other with the first and second
microchips in spaced relation and with the conductive segment or
contact joined to one nodule of the set of first nodules and one
nodule of the set of second nodules.
[0018] A surface of at least one nodule of the first set of nodules
can be generally coplanar with the top surface of the first
microchip. A surface of at least one nodule of the second set of
nodules can be generally coplanar with the top surface of the
second microchip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The systems, devices, and methods may be better understood
by referring to the following description in conjunction with the
accompanying drawings. The components in the figures are not
necessarily to scale and simply illustrate the principles of the
systems, devices, and methods. For example, elements in the figures
may be exaggerated in size to better aid in the understanding of
the portrayed embodiments. The accompanying drawings illustrate
only possible embodiments of the systems, devices, and methods and
are therefore not to be considered limiting in scope.
[0020] FIG. 1 depicts a microchip including edge interconnects or
nodules;
[0021] FIG. 2 depicts interconnecting two microchips on a substrate
via edge interconnects or nodules on each substrate;
[0022] FIG. 3 depicts difficulties in interconnecting two
microchips of different thicknesses on a substrate, where the edge
interconnects or nodules are at different heights from the surface
of the substrate;
[0023] FIG. 4 depicts interconnecting two microchips of different
thicknesses on a substrate via edge interconnects or nodules on
each substrate.
[0024] FIG. 5 depicts interconnecting two microchips using multiple
manipulators;
[0025] FIG. 6A depicts two microchips aligned in three-dimensional
space;
[0026] FIG. 6B depicts the two microchips of FIG. 6A interconnected
in three-dimensional space;
[0027] FIG. 7 depicts four microchips interconnected or positioned
to be interconnected together; and
[0028] FIG. 8 is a flow diagram of a method for interconnecting an
arbitrarily large array of microchips.
DETAILED DESCRIPTION OF THE INVENTION
[0029] It is advantageous to define several terms before describing
particular embodiments. It should be appreciated that the following
definitions are used throughout this application.
[0030] Definitions
[0031] Where the definition of terms departs from the commonly used
meaning of the term, the definitions provided below are intended,
unless specifically indicated otherwise.
[0032] For the purposes of the present description, the term
"direct electrical connection" refers to the direct contact between
interconnect nodules or between an interconnect nodule and an
electrical contact so that electrical conduction current may pass
between them.
[0033] For the purposes of the present description, the term
"electronic device" refers to electronic circuitry and any device
that includes electronic circuitry. Examples of electronic devices
include, but are not limited to, microchips, package systems,
transistors, printed circuit boards (PCBs), amplifiers, sensors,
inductors, capacitors, electrical connectors into which microchips
may be plugged, etc.
[0034] For the purposes of the present description, the term
"interposer" refers to any structure whose purpose is to extend or
complete a conductive electrical connection between two electronic
devices. In some embodiments, the conductive electrical connection
between interconnect nodules or between an interconnect nodule and
a contact may not be direct. For example, in some embodiments, a
conductive material, such as solder, may electrically connect two
interconnect nodules or an interconnect nodule with an electrical
contact. Also, in some embodiments, connectors of various types may
help conductively join interconnect nodules.
[0035] For the purposes of the present description, the term
"microchip" refers to any kind of chip having microfabricated or
nanofabricated systems built thereon. Microchips include not only
conventional integrated circuits but also Microelectromechanical
Systems (MEMS) chips and other related technologies.
[0036] For the purposes of the present description, the term
"complementary nodules" refers to two microchips containing nodules
arranged in a mirrored pattern to one another. In other words, two
microchips with complementary nodules are capable of being aligned
to form an electrical connection between the two microchips via the
nodules.
[0037] Description
[0038] Aspects of the system and methods are described below with
reference to illustrative embodiments. The references to
illustrative embodiments below are not made to limit the scope of
the claimed subject matter. Instead, illustrative embodiments are
used to aid in the description of various aspects of the systems
and methods. The description, made by way of example and reference
to illustrative reference, is not meant to being limiting with
regards to any aspect of the claimed subject matter.
[0039] Devices and methods described in this application are
particularly well-adapted for use in joining microchips
manufactured with solid edge-to-edge interconnects, such as Quilt
Packaging.RTM. interconnect technology, and will be described in
that context. However, it will become apparent that this
description is not illustrative of the only utility of the
described devices and methods.
[0040] The assembly of advanced system-in-package (SiP) designs
using innovative packaging and interconnect technology requires
substantial innovation in assembly and handling tools and methods.
Current approaches for assembling and packaging microchips are
wholly unsuited for advanced SiP designs. Accordingly, there exists
a long-felt but unaddressed need for improved apparatuses and
methods for precisely and reliably assembling advanced SiP
designs.
[0041] FIG. 1 depicts a microchip 100 configured with solid
edge-to-edge interconnects, such as those employed in microchips
configured with Quilt Packaging.RTM. interconnect technology and
described in U.S. Pat. Nos. 7,608,919 and 7,612,443 to Bernstein et
al. which are incorporated herein by reference. "Quilt Packaging"
is a U.S. registered trademark of Indiana Integrated Circuits, LLC,
U.S. Registration No. 4214679.
[0042] As shown in FIG. 1, nodules 102 made of metal or another
conductive material are located along and extend from at least one
edge 104 or surface 110 of microchip 100. These nodules 102 are
used to electrically and mechanically connect microchips together,
either through a direct electrical connection or via an interposer
(such as solder). As shown here, nodules 102 are located near the
top face 106 (or surface) of microchip 100. Generally, nodules 102
are either located contiguous to or a predetermined distance below
top face 106 of microchip 100. The placement of nodules 102 may be
standardized for a single microchip (so that all of the nodules are
located the same distance below top face 106) or across different
microchips to facilitate alignment of nodules 102 on different
microchips. However, one of skill in the art will appreciate that
nodules 102 may be placed at any point along the edge 104 of the
microchip 100, so long as the two microchips to be joined have
complementary nodules 102.
[0043] Microchip 100 is depicted in face-up orientation, such that
when microchip 100 is placed on a supporting surface 108, the face
closest to the nodules 102 (top face 106) is exposed. Conversely, a
microchip would be termed face-down if top face 106 (the face
closest to the nodules 102) were in contact with supporting surface
108, such that top face 106 was not exposed. Placing two microchips
100 configured with complementary nodules 102 adjacent to one
another, such that the nodules 102 of the first microchip 100
contact the nodules 102 of a second microchip 100, forms a direct
electrical connection between the two microchips. Alternatively,
the nodules 102 may be positioned such that they are close together
but not in direct physical contact, allowing an indirect electrical
connection between the two microchips through an interposer (such
as solder).
[0044] As described hereinafter, microchips may be joined together
in a more permanent fashion to form a stable electrical and
mechanical connection between them. An arbitrary number of
microchips may be joined together to form an arbitrarily large
array, allowing for electrical connections between each microchip
and its neighbors. To facilitate the creation of electrical and
mechanical connections between multiple microchips, in an
embodiment, these nodules 102 are created with a coating of solder.
This solder may further be used as an interposer to facilitate
indirect electrical connections.
[0045] Referring to FIG. 2, in one embodiment, a method is provided
for connecting two microchips 200a, 200b. A manipulator 204 (such
as a vacuum tool or a mechanical probe) places a first microchip
200a face-up on a substrate 206 and maneuvers microchip 200a into
position. As used herein, the term "substrate" is a supporting
surface or stage. Alternatively, first microchip 200a could be
placed into position on a package, for example, to allow two
microchips to be simultaneously joined to each other and then
immediately sealed into the package. In this instance, the package
could be placed on substrate 206 and secured into position prior to
the microchip being placed on or in the package.
[0046] Once first microchip 200a has been correctly positioned, it
is secured in place. In an embodiment, first microchip 200a is
secured in place by applying vacuum pressure via substrate 206. For
example, holes may be included in substrate 206 through which
vacuum may be applied to the back-side of first microchip 200a. The
amount of vacuum applied through each hole or subset of holes may
be individually controlled, allowing different amounts of vacuum to
exist at different locations on substrate 206. Accordingly, a
higher vacuum pressure could be applied to one microchip while a
lower vacuum pressure is applied to a second microchip--preventing
the first microchip from moving while requiring a predetermined
amount of force to move the second microchip. For example, the
necessity of using a predetermined amount of force to overcome the
vacuum and move the second microchip would decrease the likelihood
of the second microchip accidently moving. Alternatively, first
microchip 200a may be held in place by manipulator 204 or another
physical restraint, such as a clip, backstop or brace attached to
the substrate 206.
[0047] After first microchip 200a is secured in place, a second
microchip 200b is then placed on substrate 206 by manipulator 204
and aligned with first microchip 200a in the y-axis. In an
embodiment, second microchip 200b is lightly restrained against
substrate 206 by applying vacuum through holes located in substrate
206, so as to make it easier to perform the necessary fine
adjustments to properly position second microchip 200b. In another
embodiment, physical features on substrate 206 (such as grooves,
walls, etc.) are used to properly position second microchip 200b
and prevent it from moving in the y-axis. Manipulator 204 then
moves second microchip 200b along the x-axis until it is in contact
with the first microchip. More specifically, second microchip 200b
may be moved along any path until nodules 202b on second microchip
200b are in contact with nodules 202a on first microchip 200a. In
an embodiment, lateral pressure is applied between the first and
second microchips 200a, 200b (for example, by manipulator 204)
along the x-axis.
[0048] As improper alignment may result in some or all of nodules
202 failing to form electrical or mechanical connections, in an
embodiment the alignment of two or more pairs of nodules 202a, 202b
located at opposite edges of two microchips 200a, 200b are checked,
for example, through the use of machine vision or electrical
testing using a probe. As an example, if microchips 200a, 200b are
slightly misaligned or if one of the microchips is skewed, a first
pair of nodules 202 at one end of the set of nodules could be
perfectly positioned for connection while the last pair of nodules
(located at the opposite end of the chips) could be significantly
misaligned. In an embodiment, larger nodules are created at each
edge of the microchip to further facilitate proper x/y
alignment.
[0049] Referring again to FIG. 2, second microchip 200b is then
held securely in place similarly to first microchip 200a. As will
be apparent to one of skill in the art, multiple manipulators 204
could be used, for example, to secure or position both microchips
200a, 200b simultaneously or to enable microchips 200a, 200b to be
held in place without the use of vacuum or another physical
restraint on substrate 206.
[0050] After the two microchips 200a, 200b have both been secured
in place to substrate 206, microchips 200a, 200b are connected
together, both electrically and mechanically. In one embodiment,
microchips 200a, 200b are connected through a solder reflow
process. Nodules 202a, 202b, located along the edges of microchips
200a, 200b that are to be joined together, are coated in solder or
a similar material prior to positioning the two microchips 200a,
200b together. Then, when the two microchips 200a, 200b are
positioned together, nodules 202a on first microchip 200a are
placed in contact with nodules 202b on second microchip 200b.
Localized heat (e.g., from a hot air reflow gun, an infrared reflow
gun, a soldering iron, a light bulb, or another localized heat
source) is then applied to nodules 202a, 202b to melt the solder,
allowing the solder on nodules 202a to melt and merge with solder
on nodules 202b, forming multiple continuous connections between
microchips 200a, 200b at each pair of nodules 202a, 202b. The heat
is then removed from nodules 202a, 202b, allowing the reflowed
solder to cool and solidify into an unbroken electrical and
mechanical connection between the two microchips 200a, 200b.
[0051] Alternatively, heat can be applied to the entirety of both
microchips 200a, 200b (e.g., by using heaters located in the
substrate, heating the air surrounding microchips 200a, 200b, or
another generalized heat source) to raise the temperature of both
microchips 200a, 200b to some temperature T1 which is less than the
melting point of the solder. A second, localized heat source is
then used to raise the temperature of the solder on nodules 202a,
202b to a second temperature T2, which is at or above the reflow
temperature of the solder. Among other advantages, this enables the
solder to melt more quickly and avoids subjecting the entirety of
both microchips 200a, 200b to high temperatures (such as T2), which
could potentially damage microchips 200a, 200b. Additionally, a
less intense localized heat source may be used to avoid damaging
microchips 200a, 200b and to consume less power. In another
embodiment, nodules 202a, 202b on microchips 200a, 200b are joined
through a welding process, such as laser welding. Alternatively,
melted solder or a conductive epoxy can be applied to nodules 202a,
202b to form direct or indirect connections between the microchips
200a, 200b.
[0052] After microchips 200a, 200b have been connected together to
form a multi-chip device, post-processing, such as packaging, may
be performed. If microchips 200a, 200b were connected together
inside a package, the multi-chip device can then be directly
connected to the package through a process such as wire-bonding.
Alternatively, the multi-chip device may be encapsulated or
otherwise protected by the application of a protective material,
such as an epoxy or polymer.
[0053] Referring to FIG. 3, the difficulties inherent to connecting
two microchips 300a, 300b of different thicknesses is shown. In
order to form a reliable electrical connection, nodules 302a on
first microchip 300a must be properly aligned with nodules 302b on
second microchip 300b. To form a direct electrical connection, each
pair of nodules should be in direct physical contact with one
another. Alternatively, an indirect electrical connection can be
formed through the use of an interposer, such as solder. This
allows an electrical connection to be established even if the
nodules are slightly misaligned. As shown in FIG. 3, when
microchips of different thicknesses are to be connected together,
it may be difficult or impossible to form a direct electrical
connection between microchips 300a, 300b by placing them adjacent
to one another in a face-up orientation, as nodules 302a, 302b will
be located at different heights off substrate 304. Further, as
depicted in FIG. 3, if the distance between the nodules 302a on the
first microchip 300a and the nodules 302b on the second microchip
300b is great enough, it may be impossible to form a reliable
electrical connection even with the use of an interposer.
[0054] Referring to FIG. 4, a method of joining two or more
microchips 400a, 400b of different heights to form a microchip unit
is described. A first microchip 400a is placed face-down on a
substrate 406 (e.g., a stage, package, or printed circuit board) by
a manipulator 404 and maneuvered into position. The substrate 406
may be composed of a material to which solder will not adhere
(e.g., a non-metallic compound) to avoid having the microchips
400a, 400b inadvertently connected to the substrate 406. Once it is
properly positioned, first microchip 400a is secured in place.
Manipulator 404 then places a second microchip 400b face-down on
substrate 406, aligns the two microchips 400a, 400b, and moves
second microchip 400b such that nodules 402b are aligned with
nodules 402a on first microchip 400a. In an embodiment, lateral
pressure is applied along the x-axis between the first and second
microchips 400a, 400b (for example, by the manipulator 404). Second
microchip 400b is then held securely in place similarly to first
microchip 400a. As will be apparent to one of skill in the art,
multiple manipulators 404 could be used, for example, to secure or
position both microchips 400a, 400b simultaneously.
[0055] As both microchips are located face-down, the nodules 402a,
402b are located the same distance above the substrate 406
regardless of whether the two microchips 400a, 400b are of equal
thicknesses. This allows microchips manufactured from different
materials (or wafers of varying thicknesses) to be joined, so long
as the microchips have complementary nodules that are manufactured
contiguous to or a predetermined distance below the top face of the
respective microchip. As described above, modules 402a, 402b are
then joined (e.g., by using solder reflow).
[0056] Also or alternatively, substrate 406 may include a
conductive segment or contact 410 positioned in alignment with
nodules 402a, 402b when microchips 400a, 400b are positioned as
shown in FIG. 4. In an embodiment, conductive segment or contact
410 may be connected to one or more other electronic devices of
substrate 406 or disposed on substrate 406. In an embodiment,
conductive segment or contact 410 may be a conductive trace or
contact on substrate 406 which in an embodiment may be a printed
circuit board. Once nodules 402a, 402b are located in alignment
with conductive segment or contact 410 as shown in FIG. 4, nodules
402a, 402b and conductive segment or contact 410 are joined
electrically in any suitable and/or desirable manner (e.g., via
solder reflow). An advantage of nodules 402a, 402b in alignment
with conductive segment or contact 410 is the facilitation of the
visual inspection of nodules 402a, 402b and conductive segment or
contact 410 after joining together, rework of a faulty joining
together, and spacing between microchips 400a, 400b while
simultaneously forming an electrical connection between nodules
400a, 400b and conductive segment or contact 410 thereby
facilitating a flow of cooling fluid (air) between microchips 400a,
400b.
[0057] Referring to FIG. 5, a method of joining two or more
microchips 500a, 500b of different heights without using a stage or
other surface is described. As shown in FIG. 5, a first manipulator
504a positions a first microchip 500a in space. First microchip
500a is then secured in place (e.g., by locking manipulator 504a in
place). A second manipulator 504b positions a second microchip 500b
in space. For example, second manipulator 504b will align the
nodules 502a, 502b of the two microchips 500a, 500b along both the
y- and z-axes. As will be clear to one of skill in the art, this
allows for microchips of different thicknesses to be easily
connected. Second manipulator 504b is then prevented from moving in
the aligned axes. Second manipulator 504b then moves the second
microchip 500b along the x-axis until nodules 502b on second
microchip 500b contact nodules 502a on first microchip 500a. One or
both of manipulators 504a, 504b then apply lateral pressure between
microchips 500a, 500b along the x-axis. Second microchip 500b is
then secured in space (e.g., by locking second manipulator 504b
from moving). Microchips 500a, 500b are then joined, for example,
via solder reflow.
[0058] Referring to FIGS. 6A and 6B, a method of joining two or
more microchips 600a, 600b into three-dimensional (3D) arrangements
is described. A first microchip 600a is positioned on a substrate
606 using a manipulator 604 and subsequently is secured in place.
The first microchip 600a is created with holes or sockets 602a
located along its top face 608. In one embodiment, these holes are
coated in solder. A second microchip 600b is then positioned above
first microchip 600a by manipulator 604. Each of the nodules 602b
along an edge 610 of second microchip 600b is aligned with
respective holes or sockets 602a on first microchip 600a. As
described above, merely aligning a single nodule-hole pair may
cause an inadequate or non-existent connection between some nodules
602b and holes 602a if microchips 600b, 600a are misaligned or
skewed, as other nodule-hole pairs may be misaligned. Accordingly,
in an embodiment, two or more nodule-hole pairs located at opposite
ends of second microchip 600b are checked to ensure proper
alignment has been achieved.
[0059] As shown in FIG. 6B, nodules 602b on second microchip 600b
are then moved into alignment and contact holes or sockets 602a on
first microchip 600a and pressure is applied between the two
microchips 600a, 600b, for example by the manipulator 604 to press
nodules 602b into holes 602a. The two microchips 600a, 600b are
then joined, for example by using solder reflow. Additional
microchips can then be connected to either the first or second
microchip 600a, 600b in similar fashion. In an alternative
embodiment, first microchip 600a could be held by a manipulator and
positioned in space, without using a stage to support it. Second
microchip 600b could then be aligned and moved into alignment and
contact with first microchip 600a by a second manipulator. This
process could be repeated for any number of microchips, thereby
creating a three-dimensional array of interconnected
microchips.
[0060] Referring to FIGS. 7 and 8, a method of joining an arbitrary
number of microchips is described. As shown in FIG. 7, four
microchips 700a, 700b, 700c, 700d may be joined into a 2.times.2
array by first creating two pairs 702a, 702b of connected
microchips--joined together in any manner described herein. Then,
the two pairs 702a, 702b of microchips are joined together, in any
manner described herein, to form a single array composed of four
interconnected microchips 700a, 700b, 700c, 700d.
[0061] As will be understood by one of skill in the art, an
arbitrary number of microchips could be joined together in any
manner described herein together in any manner described herein in
similar fashion. For example, a system comprised of an odd number
of microchips could be formed by first forming and connecting pairs
of microchips and then joining a single unpaired microchip.
Similarly, an arbitrary number of microchips of different shapes or
sizes could be joined into an interconnected array using this
technique. For example, nodules may be located along the interior
edges of all microchips in the array, forming electrical and
mechanical connections between all adjacent microchips and allowing
each microchip to communicate directly with all adjacent
microchips. Similarly, microchips may relay signals, so as to allow
non-adjacent microchips in the array to communicate. Additional
nodules could be formed along exterior edges, for example to allow
additional microchips or other electrical devices to be connected
to the array.
[0062] FIG. 8 depicts a generalized process for creating an
arbitrarily large array of interconnected microchips. As described
above, in step 800, two microchips are joined (creating a pair of
microchips). At step 802, a determination is made if additional
microchips need to be added to the array. If no microchips need to
be added, then the process ends at step 810. If more microchips
need to be added, then a determination is made at step 804 whether
there are two or more microchips to add. If so, then two microchips
are joined into a pair at step 806 and are added to the array at
step 808. The process then repeats by checking whether more
microchips need to be added at step 802. Alternatively, if there is
only a single microchip to add at step 804, then the single
microchip is added at step 812 and the process ends at step
814.
[0063] As will be clear to one of ordinary skill in the art, the
process described in FIG. 8 creates an array of microchips that is
two microchips wide and an unlimited number of microchips long.
Alternatively, the process may be modified to create an array of
arbitrary size. For example, a 8.times.8 array of sixty-four square
microchips could be created by first creating thirty-two pairs of
microchips, as described above. Each pair (or 2.times.1 array) is
then treated as a single microchip, and paired again to create
sixteen 2.times.2 arrays. The process repeats, successively pairing
microchips to create eight 4.times.2 arrays, four 4.times.4 arrays,
two 8.times.4 arrays, and finally a single 8.times.8 array. A
similar form of this process could be used to join microchips of
any shape into an array of arbitrary size.
[0064] What has been described above includes examples of aspects
of the claimed subject matter. It is, of course, not possible to
describe every conceivable combination of components or
methodologies for purposes of describing the claimed subject
matter, but one of ordinary skill in the art may recognize that
many further combinations and permutations of the disclosed subject
matter are possible. Accordingly, the disclosed subject matter is
intended to embrace all such alterations, modifications, and
variations that fall within the spirit and scope of the appended
claims. Furthermore, to the extent that the terms "includes",
"has", "having", or variations in form thereof are used in either
the detailed description or the claims, such terms are intended to
be inclusive in a manner similar to the term "comprising" as
"comprising" is interpreted when employed as a transitional word in
a claim.
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